Repair manual
Ford Five Hundred I Repair Manual
Step-by-step repair and maintenance instructions for the Ford Five Hundred I (2004–2007): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
83sections
729articles
ENManual language
- GENERAL SPECIFICATIONS CHART
- GEAR AND SOLENOID OPERATION CHART
- GEAR RATIO REFERENCE CHART
- SHIFT SPEED MANUAL D POSITION (MINIMUM THROTTLE)
- SHIFT SPEED MANUAL L POSITION
- ENGINE RPM SPECIFICATION
- SOLENOID RESISTANCE READING
- CLUTCH AND BRAKE PRESSURE CHART
- TORQUE SPECIFICATIONS CHART
- Transaxle Description
- Identification Tags
- Range Selection
- Park
- Reverse
- Neutral
- Drive
- Manual L Position
- Shift Patterns
- Downshifts
- Coastdown
- Torque Demand
- Kickdown
- Automatic Gearshift Control
- Driver Adaptive Shift Control
- Gear Shift Control
- Reverse Converter Control
- Torque Converter Control
- Torque Converter
- Geartrain
- Differential
- C-1 Clutch
- C-2 Clutch
- C-3 Clutch
- B-1 Brake
- B-2 Brake
- F-1 One-Way Clutch
- Valve Body
- Electronic System Description
- Transmission Control Module (TCM) Control Function
- Brake Pedal Position (BPP) Switch
- Speed Sensor
- Adaptive Shift Control
- Diagnostic Strategy
- Preliminary Inspection
- Diagnostics
- Diagnostic Flow Chart
- Special Tool(s)
- Know and Understand the Concern
- Verification of Condition
- Determine Customer Concern
- Check Fluid Level and Condition
- Fluid Level Check
- High Fluid Level
- Low Fluid Level
- Adding Fluid
- Fluid Condition Check
- Road Testing Vehicle
- Visual Inspection
- Shift Linkage Check
- Check TSBs
- Carry Out On-Board Diagnostics (KOEO, KOER)
- Self Diagnosis Function
- Fail-Safe
- On-Board Diagnostic With Diagnostic Tool
- Transaxle Drive Cycle Test
- After On-Board Diagnostics
- Before Pinpoint Tests
- Diagnostic Trouble Code Chart
- PINPOINT TEST A: SHIFT SOLENOIDS
- Engine Idle Speed Check
- Stall Speed Test
- Pressure Diagnostic Chart
- Leakage Inspection
- External Fluid Leaks
- External Sealing
- Fluid Leakage in Torque Converter Area
- Leak Check Test
- Diagnosis by Symptom Chart Directions
- Diagnosis by Symptom Index
- Other Concerns: Transmission Fluid Level
- Other Concerns: Transmission Fluid Condition
- Other Concerns: Transmission Control Module Software
- Engagement Concerns: No Forward and/or No Reverse
- Engagement Concerns: Harsh
- Engagement Concerns: Soft
- Torque Converter Clutch Operations Concerns: Does Not Apply
- Torque Converter Clutch Operations Concerns: Cycling/Shutter/Chatters
- Material
- Removal
- Installation
- Disassembly
- Assembly
- GENERAL SPECIFICATIONS
- FORWARD CLUTCH PACK
- REVERSE CLUTCH PACK
- INPUT SHAFT END PLAY SPECIFICATION
- DIFFERENTIAL BEARING RACE SELECTIVE SHIM SPECIFICATION
- TORQUE SPECIFICATIONS
- Transaxle Description
- Internal Fluid Filter
- Range Selection
- Park
- Reverse
- Neutral
- Drive
- Low
- Torque Converter
- Torque Converter Clutch
- Fluid Pump
- Variator Assemblies
- Transaxle Electronic Control System
- Mechatronic Assembly
- Main Control Valve Body
- Pressure Control Solenoids
- Pressure Sensors
- Transmission Control Module (TCM)
- TCM monitored inputs from other electronic modules
- Transmission Fluid Temperature (TFT) Sensor
- Speed Sensors
- Turbine Shaft Speed (TSS) Sensor and Primary Variator Speed Sensor
- Output Shaft (OSS) Sensor
- Transmission Range Sensor
- Diagnostic Strategy
- Preliminary Inspection
- Diagnostics
- Diagnostic Flow Chart
- Special Tool(s)
- Know and Understand the Concern
- Verification of Condition
- Determine Customer Concern
- High Fluid Level
- Low Fluid Level
- Adding Fluid
- Fluid Condition Check
- Torque Converter Operation Test
- Visual Inspection
- Shift Linkage Check
- Check TSBs
- Carry Out On-Board Diagnostics (KOEO, KOER)
- On-Board Diagnostic (OBD) With Diagnostic Tool
- Diagnostic PID Chart
- Diagnostic Trouble Code Chart
- Worldwide Diagnostic System (WDS)
- PINPOINT TEST A: TRANSMISSION FLUID PRESSURE SENSORS
- PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR
- PINPOINT TEST C: TRANSMISSION RANGE (TR) SENSOR
- PINPOINT TEST D: TORQUE CONVERTER CLUTCH
- PINPOINT TEST E: EXCESSIVE CLUTCH SLIPPAGE
- PINPOINT TEST F: OUTPUT SHAFT SPEED (OSS) SENSORS
- PINPOINT TEST G: TURBINE SHAFT SPEED (TSS) SENSOR
- PINPOINT TEST H: TRANSMISSION CONTROL MODULE SIGNAL
- PINPOINT TEST I: PRIMARY PULLEY SPEED SENSOR
- Material
- Fluid Leakage in Torque Converter Area
- Leak Check Test
- Leak Check Test With A Black Light
- Diagnosis by Symptom Chart Directions
- Diagnosis by Symptom Index
- Engagement Concern: No Forward
- Engagement Concern: No Reverse
- Engagement Concern: Harsh Reverse
- Engagement Concern: Harsh Forward
- Engagement Concern: Delayed/Soft Reverse
- Engagement Concern: Delayed/Soft Forward
- Engagement Concern: No Forward and No Reverse
- Torque Converter Operation Concerns: No Apply
- Torque Converter Operation Concern: Cycling/Shudder/Chatter
- Other Concerns: Shift Lever Efforts High
- Other Concerns: External Leaks
- Other Concerns: Noise/Vibration - Forward or Reverse
- Other Concerns: No Park Range
- Other Concerns: Transaxle Overheating
- Drain
- Removal
- Installation — Part 1
- Installation — Part 2
- Disassembly
- Assembly
- Disassembly and Assembly — Part 1
- Disassembly and Assembly — Part 2
- VECI Decal
- VECI Decal Location
- Engine/Evaporative Emission (EVAP) System Information
- Base Engine Calibration Information
- Decal Location
- Engine Calibration Code
- VECI Acronym Definitions
- OBD-I and OBD-II Overview
- Catalyst Efficiency Monitor
- Switch Ratio Method
- Index Ratio Method
- General Catalyst Monitor Operation
- Comprehensive Component Monitor (CCM)
- Evaporative Emission (EVAP) Leak Check Monitor
- Engine On EVAP Leak Check Monitor
- Engine Off Natural Vacuum (EONV) EVAP Leak Check Monitor
- Exhaust Gas Recirculation (EGR) System Monitor - Delta Pressure Feedback (DPFE) EGR and EGR System Module (ESM)
- Electric Exhaust Gas Recirculation (EEGR) System Monitor
- Fuel System Monitor
- Heated Oxygen Sensor (HO2S) Monitor
- Misfire Detection Monitor
- Misfire Monitor Operation
- Low Data Rate System (LDR)
- High Data Rate System (HDR)
- Generic Misfire Processing
- Profile Correction
- Misfire Monitor Specifications
- Positive Crankcase Ventilation (PCV) System Monitor
- Secondary Air Injection (AIR) System Monitor - Electric Secondary Air Injection Pump System
- Thermostat Monitor
- Variable Cam Timing (VCT) Monitor
- Malfunction Indicator Lamp (MIL)
- Overview
- Modifications to OBD Vehicles
- Multiplexing
- Multiplexing Implementation
- Standard Corporate Protocol (SCP)
- High Speed Controller Area Network (CAN)
- Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
- Idle Air Trim
- Short Term Fuel Trim
- Long Term Fuel Trim
- Idle Speed Control Closed Throttle Determination (applications without Electronic Throttle Control)
- Fail-Safe Cooling Strategy
- Failure Mode Effects Management
- Engine RPM/Vehicle Speed Limiter
- Powertrain Control Module (PCM)
- PCM Locations
- Fuel Injector Control Module
- Fuel Pump Driver Module (FPDM)
- Keep Alive Memory (KAM)
- Hardware Limited Operation Strategy (HLOS)
- Integrated Electronic Ignition System
- Electronic Throttle Control Reference Voltage (ETCREF)
- Electronic Throttle Control Return (ETCRTN)
- Gold Plated Pins
- Keep Alive Power (KAPWR)
- Mass Air Flow (MAF) Return
- Power Ground (PWR GND)
- Signal Return (SIG RTN)
- Vehicle Buffered Power (VBPWR)
- Vehicle Power (VPWR)
- Vehicle Reference Voltage (VREF)
- Powertrain Control Module (PCM) Inputs
- Accelerator Pedal Position (APP) Sensor
- Air Conditioning (A/C) Cycling Switch
- Air Conditioning Evaporator Temperature (ACET) Sensor
- Air Conditioning (A/C) Pressure Sensor
- Air Conditioning (A/C) High Pressure Switch
- Brake Pedal Position (BPP) Switch
- Brake Pedal Switch (BPS)/Brake Deactivator Switch
- Camshaft Position (CMP) Sensor
- Clutch Pedal Position (CPP) Switch
- Crankshaft Position (CKP) Sensor
- Cylinder Head Temperature (CHT) Sensor
- Differential Pressure Feedback EGR (DPFE) Sensor
- Electronic Throttle Body (ETB) Position Sensor
- Engine Coolant Temperature (ECT) Sensor
- Engine Oil Temperature (EOT) Sensor
- Fuel Level Input
- Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control
- Fuel Pump Driver Module (FPDM) Applications
- Fuel Rail Pressure (FRP) Sensor
- Fuel Rail Pressure Temperature (FRPT) Sensor
- Fuel Rail Temperature (FRT) Sensor
- Fuel Tank Pressure (FTP) Sensor
- Generator Load Input (GENLI)
- Heated Oxygen Sensor (HO2S)
- Intake Air Temperature (IAT) Sensor
- Intake Manifold Runner Control Monitor (IMRCM) - Electric Actuated
- Intake Manifold Runner Control Monitor (IMRCM) - Vacuum Actuated
- Knock Sensor (KS)
- Mass Air Flow (MAF) Sensor
- Output Shaft Speed (OSS) Sensor
- Power Steering Pressure (PSP) Switch
- Power Steering Pressure (PSP) Sensor
- Power Take-Off (PTO) Switch and Circuits
- PTO Circuits Description
- Starter Motor Request (SMR) Circuit
- Throttle Position (TP) Sensor
- Transmission Control Switch (TCS)
- Vehicle Speed Sensor (VSS)
- Four-Wheel Drive (4WD) Mode Switch
- Powertrain Control Module (PCM) Outputs
- Air Conditioning Clutch Relay (A/CCR)
- Canister Vent (CV) Solenoid
- Coil Pack
- Coil On Plug (COP)
- Engine Crank/Engine Running
- CMP FMEM
- Electric EGR (EEGR) System
- EGR System Module (ESM)
- EGR Vacuum Regulator (EVR) Solenoid
- Electric Secondary Air Injection Pump
- Evaporative Emission (EVAP) Canister Purge Valve
- Fan Control
- Fuel Cap Indicator Lamp
- Fuel Pump Driver Module (FPDM) Applications (and Applications with Fuel Pump Functions Incorporated in Rear Electronic Module)
- Fuel Injectors
- Fuel Pressure Regulator Control (FPRC) Solenoid
- Generator Regulator Control (GENRC)
- High Fan Control
- Idle Air Control (IAC) Solenoid
- Intake Manifold Runner Control (IMRC) - Electric Actuated
- Intake Manifold Runner Control (IMRC) - Vacuum Actuated
- Intake Manifold Tuning Valve (IMTV)
- Low Fan Control
- Medium Fan Control
- Reverse Lamp Control (RLC)
- Secondary Air Injection Bypass Solenoid
- Transmission Control Indicator Lamp (TCIL)
- Vapor Management Valve (VMV)
- Powertrain Control Module - Vehicle Speed Output (PCM-VSO)
- Wide Open Throttle A/C Cut-Off (WAC)
- Integrated Electronic Ignition (EI) System
- Returnable Fuel System
- Mechanical Returnless Fuel System
- Electronic Returnless Fuel System
- Fuel Pump Module and Reservoir
- Fuel Pump Module
- Fuel Filters
- Pressure Test Point
- Fuel Injector
- Fuel Pressure Regulator
- Fuel Rail Pulse Damper
- Inertia Fuel Shutoff (IFS) Switch
- Differential Pressure Feedback EGR (DPFE) System
- Tube Mounted Differential Pressure Feedback EGR (DPFE) Sensor
- Exhaust Gas Recirculation (EGR) Valve
- Orifice Tube Assembly
- Highlights of the EEGR System
- Hardware
- Enhanced Evaporative Emission (EVAP) System
- EVAP Canister Purge Valve
- Intake Manifold Runner Control (IMRC) Electric Actuated System
- Intake Manifold Runner Control (IMRC) Vacuum Actuated System
- Throttle Body System Overview
- Throttle Body System Hardware
- Idle Air Control (IAC) Valve (Applications Without ETC)
- Throttle Body Housing
- Electric Secondary AIR System
- Electric AIR Pump
- AIR Bypass Solenoid
- AIR Diverter Valve
- Variable Cam Timing (VCT) System
- Heated Tubes
- PCV Valves
- Catalytic Converter
- Light Off Catalyst
- Three-Way Catalyst (TWC) Conversion Efficiency
- Exhaust System
- Underbody Catalyst
- Three-Way Catalytic Converter
- Exhaust Manifold Runners
- Exhaust Pipes
- Heated Oxygen Sensors (HO2S)
- Muffler
- Supercharger Bypass (SCB) System
- Supercharger Assembly
- Supercharger Bypass (SCB) Solenoid/(Thermactor Air Control Solenoid/Vacuum Valve Assembly)
- Vacuum Reservoir Assembly
- Intercooler System
- Electronic Throttle Body (ETB)
- Electronic Throttle Control (ETC) System Strategy
- Accelerator and Throttle Position (TP) Sensor Inputs
- Throttle Plate Position Controller (TPPC) Outputs
- Fuel Select Switch Circuit
- Fuel Rails
- Fuel Injector Control Module (FICM)
- TORQUE SPECIFICATIONS
- Headlamps
- Autolamps
- Turn Signal and Hazard Lamps
- Parking, Rear or License Lamps
- Fog Lamps
- Reversing Lamps
- Special Tool(s)
- Principles of Operation
- Inspection and Verification
- Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index
- Symptom Chart
- Normal Operation
- Possible Causes
- Normal Operation - Halogen Low Beams
- Normal Operation - High Intensity Discharge (HID) Low Beams
- Stoplamps
- Normal Operation - Freestyle and Five Hundred
- Normal Operation - Montego
- Pinpoint Test M: The Turn Signal Lamps Are Always On
- Normal Operation - Five Hundred and Freestyle
- Testing
- Parking, Rear and License Lamps
- Headlamp Aiming
- Photometric Aiming
- Mechanical Aiming
- Removal
- Installation
- Removal and Installation
- Side Lamp/Front Turn Signal Lamp Bulb
- TORQUE SPECIFICATIONS
- Special Tool(s)
- Principles of Operation
- Power Door Locks
- Autolocking
- Luggage Compartment Lid Release
- Remote Keyless Entry (RKE)
- Smart Unlock
- Inspection and Verification
- Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index
- Symptom Chart
- Normal Operation
- Possible Causes
- Testing
- Remote Keyless Entry Keypad Code Programming
- Remote Keyless Entry Transmitter Programming
- Removal and Installation
- Removal
- Installation
- GENERAL SPECIFICATIONS CHART
- Climate Control System
- Principles of Operation
- Heat Transfer
- Latent Heat of Vaporization
- Relative Humidity
- Effects of Pressure on Boiling or Condensation
- Compressor Anti-Slugging Strategy
- The Refrigerant Cycle
- Electronic Manual Temperature Control System
- Electronic Automatic Temperature Control System
- Auxiliary Climate Control System
- Max A/C
- PANEL
- PANEL/FLOOR
- OFF
- FLOOR
- FLOOR/DEFROST
- DEFROST
- AUTO
- Special Tool(s)
- Inspection and Verification
- Electronic Automatic Temperature Control Module - Diagnostic Methods
- Electronic Automatic Temperature Control Module On-Demand Self Test
- Electronic Automatic Temperature Control Module - Retrieve Continuous DTCs
- Electronic Automatic Temperature Control (EATC) Module Diagnostic Trouble Code (DTC) Index
- Symptom Chart
- Normal Operation
- Possible Causes
- Testing
- Door actuator feed A circuits
- Door actuator feed B circuits
- Door actuator return circuits
- Door actuator reference circuits
- Door actuator feedback circuits
- Heater Core
- Heater Core - Plugged
- Heater Core - Pressure Test
- Evaporator/Condenser Core - On-Vehicle Leak Test
- A/C Compressor - External Leak Test
- Air Conditioning (A/C) System Check - Retail Procedure
- Visual inspection
- Disconnect
- Connect
- Fluorescent Dye Detection
- Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector
- Fluorescent Dye Injection - Using a Dye Injector Loop Kit
- Leak Detection
- Material
- System Flushing
- Refrigerant System Recovery
- Refrigerant System Evacuation Using an R-134a Service Center
- Refrigerant System Evacuation Using an R-134a Manifold Gauge Set
- Refrigerant System Charging Using an R-134a Service Center
- Refrigerant System Charging
- Refrigerant Oil Adding
- Refrigerant Oil Adding for New A/C Compressor Installation
- Refrigerant Oil Adding for New Suction Accumulator or Receiver/Drier Installation
- Oil Injection Using a Dye/Lubricant Injector
- Refrigerant Identification
- Contaminated Refrigerant Handling
- A/C Odor Treatment
- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- Rear View Mirrors
- Special Tool(s)
- Exterior Power Mirrors
- Memory Exterior Mirror
- Heated Exterior Mirror
- Auto-Dimming Interior Mirror
- Inspection and Verification
- Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index
- Symptom Chart
- Normal Operation
- Possible Causes
- Testing
- Exterior Mirrors - Exploded View
- Removal and Installation
- Installation
- TORQUE SPECIFICATIONS
- Front Seats
- Driver Seat Module - Memory Seat
- Heated Seats
- Occupant Classification Sensor (OCS)
- Five Hundred and Montego
- Freestyle
- Third Row Seating
- Seats
- Special Tool(s)
- Restraint System Diagnostic Tool Warning
- Diagnostic Tool and Controller Area Network Note
- Driver and Passenger Power Seats Without Memory
- Power Driver Seat With Memory
- Seat Calibration
- Programming Memory Seat Positions
- Recalling a Stored Memory Seat Position
- Inspection and Verification
- Driver Seat Module (DSM) Diagnostic Trouble Code (DTC) Index
- Symptom Chart
- Pinpoint Tests
- Normal Operation
- Possible Causes
- Testing
- Removal
- Seat - Exploded View, Front
- Removal and Installation
- Installation
- Seat - Exploded View, Second Row, Five Hundred, Montego
- Seat - Exploded View, Third Row
- Disassembly
- Assembly
- MATERIAL SPECIFICATIONS
- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- Glass, Frames and Mechanisms
- Special Tool(s)
- LH Front Power Window Control
- Passenger Window Operation
- Delayed Accessory Power
- Rear Window Defrost
- Inspection and Verification
- Smart Junction Box (SJB) Diagnostic Trouble Code (DTC) Index
- Symptom Chart
- Normal Operation
- Possible Causes
- Pinpoint Test B: A Single Power Window Is Inoperative - LH Front
- RH Front Window Operation From LH Front Switch
- Rear Window Operation From LH Front Switch
- Pinpoint Test E: The One-Touch Up/Down Feature Is Inoperative - LH Front Window Only
- Material
- Repair
- Door Window Motor Initialization
- De-initialization procedure
- Removal and Installation
- Glass, Frames and Mechanisms - Exploded View, Rear Door
- Installation
- Removal
- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- Wipers and Washers
- Special Tool(s)
- Windshield Wiper and Washers
- High Speed Windshield Wipers
- Low Speed Windshield Wipers
- Intermittent Windshield Wipers
- Software Safe Mode
- Windshield Washer - Five Hundred and Montego
- Windshield Washer - Freestyle
- Rear Window Washer - Freestyle
- Rear Window Wiper and Washer - Freestyle
- Smart Junction Box (SJB)
- Inspection and Verification
- SJB Diagnostic Trouble Code (DTC) Index
- Symptom Chart
- Normal Operation
- Possible Causes
- Testing
- PINPOINT TEST F: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY (HIGH/LOW SPEEDS OK)
- Windshield Washer Pump and Reservoir